Letterpress application of elastomeric compositions

ABSTRACT

A process of manufacturing a stretch composite is disclosed. The process comprises providing a polyolefin based substrate, providing a letterpress adhesive application system comprising a pattern roll and an applicator roll, and depositing a molten, non-adhesive, elastomeric composition onto the applicator roll. The process further comprises transferring only a portion of the elastomeric composition that is on the applicator roll, from the applicator roll to the pattern roll, by contacting the pattern roll with the elastomeric composition that is on the applicator roll, and transferring substantially all of the elastomeric composition from the pattern roll to the substrate, by contacting the substrate with the elastomeric composition that is on the pattern roll, without damaging the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/644,065, filed on Dec. 22, 2009, now U.S. Pat. No. 8,496,776, grantedon Jul. 30, 2013,which is a divisional of U.S. patent application Ser.No. 11/087,345, filed on Mar. 23, 2005, now U.S. Pat. No. 7,658,811,granted on Feb. 9, 2010, which claims the benefit of U.S. ProvisionalPatent Application Ser. No. 60/557,272, filed on Mar. 29, 2004. Priorityis claimed to all of the above-listed patent applications. The entiredisclosures of all of the above-listed patent applications are herebyincorporated by reference herein.

FIELD

The disclosure generally relates to a process of forming a stretchcomposite via transfer of elastomeric compositions onto a substrate vialetterpress application. In this process, an elastomeric composition issubstantially removed from raised surface elements of a pattern roll,i.e., the residual elastomer is less than 10%. In certain embodiments,the composite is subsequently incrementally stretched to at leastpartially break up the structure of the substrate in order to reduce itsresistance to stretch. The stretch composites are useful for disposablearticles, such as disposable absorbent articles including diapers,pull-on diapers, training pants, incontinence briefs, catamenialgarments, baby bibs, and the like, and other disposable and durablearticles, particularly garments including surgical garments and drapes,sportswear, outerwear and the like.

BACKGROUND

Disposable absorbent products (e.g., disposable diapers) typicallyinclude stretchable materials, such as elastic strands, in the waistregion and the cuff regions to provide a snug fit and a good seal to awearer's body. Pant-type absorbent articles further include stretchablematerials in the side portions for easy application and removal of thearticle and for sustained fit of the article. Stretchable materials havealso been used in the ear portions of taped diapers for adjustable fitof the article. Useful stretchable materials include elastomeric films,nonwovens, strands of natural or synthetic rubber, elastic scrim, andthe like. Typically, these stretch regions are made separately andattached to the diaper using adhesives. In most cases, these designsdeliver uniform and unidirectional stretch. Similarly, garments, bothdisposable and durable, also use elastic elements for improved fit andcomfort.

An alternate approach that is capable of delivering multidirectional,non-uniform stretch has been disclosed in copending U.S. patentapplication Ser. Nos. 10/288,095, 10/288,126 and 10/429,433. Thisapproach involves hot melt printing of one or more thermoplasticelastomers onto a substrate, followed by incremental stretching of theelasticized substrate that then confers the stretch properties of theelastomer to the substrate in a somewhat magnified form. Suitableprinting processes disclosed therein include direct gravure, offsetgravure, and flexographic printing. Each of these printing methodsallows deposition of a predetermined amount of an elastomer in any shapeand direction, thus giving a wide variety of design flexibility whichultimately results in improved fit of the overall diaper product.However, improvements are still needed.

Desirably, transfer of such an elastomeric composition from the meansused to apply the elastomer to a substrate is substantially complete.Otherwise, the elastomeric composition can oxidize with resulting colordegradation, or suffer degradation of other properties. Suchdegradation, as may result from incomplete transfer is more likely ifthe application means is heated.

Without being limited by theory, it is therefore important to understandthe mechanism of transfer of an elastomer from an application means to asubstrate. During this transfer, three forces are relevant. These forcesinclude: i) the adhesive force between the surface of the applicationmeans and the elastomer; ii) the cohesive strength of the elastomer(i.e., the resistance of a single portion of an elastomeric compositionto separation into two smaller portions); and iii) the adhesive forcebetween the elastomer and the substrate and/or the strength of thesubstrate. In order to successfully transfer an elastomer to a substrateeither one or both of the cohesive strength of the elastomer or theadhesive force between the elastomer and the surface of the applicationmeans must be less than the adhesive force between the elastomer and thesubstrate and/or the strength of the substrate. Typically, this problemhas been solved by the use of heated printing processes where thecohesive strength of the heated elastomer is at a sufficiently low valuebecause the elastomer has been maintained in a liquid or semi-liquidstate. Thus, transfer of an elastomeric composition from an applicationmeans to a substrate typically is achieved through cohesive failure ofthe elastomer at the point of transfer from the application means to thesubstrate and a portion of the elastomer remains on the surface of theapplication means. The above conditions generally apply during, forexample, gravure printing of elastomeric adhesives, where the viscosityis relatively low and the adhesive has strong affinity for the walls ofthe gravure elements and also the substrate. Importantly, cohesivefailure means that there is a residual portion of adhesive on theapplication means that is not transferred.

On the other hand, elastomeric compositions that have good elasticitygenerally have a higher viscosity at a given temperature than a typicalelastomeric adhesive. For reference, typical thermoplastic elastomersused in diapers have viscosities in excess of 1000 Pa·S at 175° C.Increased viscosity translates into a higher cohesive force of theelastomer and a need to heat to a higher application temperature toinsure cohesive failure. Such a dynamic poses a problem for conventionaldirect gravure printing of high viscosity materials, since a point isreached when the cohesive strength of the elastomer either exceeds itsadhesive strength with the substrate or it exceeds the strength of thesubstrate. Such conditions, in turn, result in either a failure of theelastomer to bond to the substrate or damage to the substrate. On theother hand, if temperature is increased to lower cohesive strength, theapplication temperature of the elastomeric composition may exceed themelting point of the substrate with resulting substrate damage orthermal degradation of the elastomer. Thus, there is a need for anapplication process that is capable of depositing high viscosityelastomeric compositions on substrates, without damaging thesesubstrates.

SUMMARY

In one form, the present disclosure generally relates, in part, to aprocess of manufacturing a stretch composite. The process may compriseproviding a polyolefin based substrate, providing a letterpress adhesiveapplication system comprising a pattern roll and an applicator roll, anddepositing a molten, non-adhesive, elastomeric composition onto theapplicator roll. The process may further comprise transferring only aportion of the elastomeric composition that is on the applicator roll,from the applicator roll to the pattern roll, by contacting the patternroll with the elastomeric composition that is on the applicator roll,and transferring substantially all of the elastomeric composition fromthe pattern roll to the substrate, by contacting the substrate with theelastomeric composition that is on the pattern roll, without damagingthe substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings, in which:

FIG. 1 is a schematic view of an apparatus for carrying out oneembodiment of the process of the present invention.

FIG. 2 is a perspective view of an apparatus for carrying out theprocess of the present invention.

FIG. 3 is a perspective view of an apparatus for incrementallystretching an elasticized substrate produced according to the process ofthe present invention.

FIG. 4 a is a perspective view of a sample holder used in the peel test.

FIG. 4 b is a perspective view of a clamp used in the peel test.

DETAILED DESCRIPTION

Definitions

The term “disposable” as used herein refers to products which generallyare not intended to be laundered or otherwise restored or extensivelyreused in their original function, i.e., preferably they are intended tobe discarded after about 10 or fewer uses, or more preferably afterabout 5 or fewer uses, or even more preferably after about a single use.It is preferred that such disposable articles be recycled, composted orotherwise disposed of in an environmentally compatible manner.

The term “disposable absorbent article” as used herein refers to adevice that normally absorbs and retains fluids. In certain instances,the phrase refers to devices that are placed against or in proximity tothe body of the wearer to absorb and contain the excreta and/or exudatesdischarged from the body, and includes such personal care articles asfastened diapers, pull-on diapers, training pants, swim diapers, adultincontinence articles, feminine hygiene articles, and the like. In otherinstances, the term also refers to protective or hygiene articles, forexample, bibs, wipes, bandages, wraps, wound dressings, surgical drapes,and the like.

The term “adhesive” refers to materials that, when evaluated accordingto the peel test described in the TEST METHODS section below have a peelforce greater than 3 N/cm.

The term “substrate” as used herein refers to a material that includeseither a natural or synthetic material or any combination thereof, forexample, nonwoven webs, woven webs, knitted fabrics, films, filmlaminates, nonwoven laminates, sponges, foams, and any combinationsthereof.

The term “fibrous substrate” as used herein refers to a materialcomprised of a multiplicity of fibers that could be either a natural orsynthetic material or any combination thereof, for example, nonwovenwebs, woven webs, knitted fabrics, and any combinations thereof.

The term “nonwoven” as used herein refers to a material made fromcontinuous and/or discontinuous fibers, without weaving or knitting, byprocesses such as airlaying, wet laying, spun-bonding, carding andmelt-blowing. A nonwoven web can comprise one or more nonwoven layers,wherein each layer can include continuous and/or discontinuous fibers.Nonwoven webs can also comprise bicomponent fibers, which can haveshell/core, side-by-side, or other known fiber structures.

The term “elastic” or “elastomeric” as used herein refers to anymaterial that upon application of a biasing force, can stretch to anelongated length of at least about 160 percent of its relaxed, originallength, without rupture or breakage, and upon release of the appliedforce, recovers at least about 55% of its elongation, preferablyrecovers substantially to its original length that is, the recoveredlength being less than about 120 percent, preferably less than about 110percent, more preferably less than about 105 percent of the relaxedoriginal length.

The term “inelastic” refers herein to any material that does not fallwithin the definition of “elastic” above.

The term “elastomer” as used herein refers to a polymer exhibitingelastic properties.

The term “extensible” or “inelastically elongatable” refers herein toany material that upon application of a biasing force to stretch beyondabout 110 percent of its relaxed original length will exhibit permanentdeformation, including elongation, rupture, breakage, and other defectsin its structure, and/or changes in its tensile properties.

The term “letterpress” or “letterpress application system” refers hereinto application means where a material is transferred to a substrate froman apparatus comprising a predetermined pattern of raised surfaceelements on a metallic roll surface where the shape of the individualelements defines the shape of the transferred material.

The term “necked material” refers to any material that has been narrowedin one direction by the application of a tensioning force.

The terms “machine direction” or “MD” as used herein refer to thedirection of material flow through a process. The terms “cross machinedirection” or “CD” refer to a direction perpendicular to the machinedirection.

Substrate

Substrates (i.e., a first substrate or any additional substrate layers)suitable for use in the presently claimed processes have opposed firstand second surfaces and may be selected from the group consisting oftissue, films, knitted fabric, woven fibrous webs, nonwoven fibrous webs(including air laid, wet laid, carded, meltblown and spunbonded webs),or combinations thereof. In some embodiments, the substrate is anextensible nonwoven web that comprises polyolefin fibers and/orfilaments, such as polyethylene, polypropylene, etc. The substrate canalso be a nonwoven-film laminate, which for example, may be used as theouter cover of a disposable diaper, training pant, adult incontinenceproduct, etc. Ideally, the substrate has a thickness between about 0.05mm and about 2 mm, preferably from about 0.1 mm to about 1 mm, and mostpreferably, from about 0.1 mm to about 0.5 mm.

Elastomeric Composition

The elastomeric composition of the present invention is characterized ashaving a peel force of less than about 3 N/cm, more preferably, lessthan about 2 N/cm, even more preferably, less than about 1 N/cm, andmost preferably, less than about 0.8 N/cm. (The methodology used todetermine the peel force of these elastomeric compositions is discussedin the TEST METHODS section below). As is discussed below, suchrelatively low peel force is believed necessary in order to achievesubstantially complete transfer onto a substrate from a pattern roll.

Suitable elastomeric compositions comprise thermoplastic elastomersselected from the group consisting of styrenic block copolymers having asoft block comprising an olefin (preferred olefins include isoprene,butadiene, ethylene, propylene, butylene, and isobutylene),metallocene-catalyzed polyolefins, polyesters, polyurethanes, polyetheramides, and combinations thereof. Suitable styrenic block copolymers maybe diblock, triblock, tetrablock, or other multi-block copolymers havingat least one styrenic block. Such multi-block copolymers include bothlinear multi-block copolymers and branched copolymers where a pluralityof blocks radiate out from a central block, commonly known as starpolymers. Exemplary styrenic block copolymers includestyrene-butadiene-styrene, styrene-isoprene-styrene,styrene-ethylene/butylene-styrene, styrene-ethylene/propylene-styrene,and the like. Commercially available styrenic block copolymers includeKRATON® from the Shell Chemical Company of Houston, Tex.; SEPTON® fromKuraray America, Inc. of New York, N.Y.; and VECTOR® from Dexco ChemicalCompany of Houston, Tex. Commercially available metallocene-catalyzedpolyolefins include EXXPOL® and EXACT® from Exxon Chemical Company ofBaytown, Tex.; AFFINITY® and ENGAGE® from Dow Chemical Company ofMidland, Mich. Commercially available polyurethanes include ESTANE® fromNoveon, Inc., Cleveland, Ohio. Commercial available polyether amidesinclude PEBAX® from Atofina Chemicals of Philadelphia, Pa. Commerciallyavailable polyesters include HYTREL® from E. I. DuPont de Nemours Co.,of Wilmington, Del.

The elastomeric compositions may further comprise processing aids and/orprocessing oils to adjust the melt viscosity of the compositions. Theyinclude the conventional processing oil, such as mineral oil, as well asother petroleum-derived oils and waxes, such as paraffinic oil,naphthenic oil, petrolatum, microcrystalline wax, paraffin orisoparaffin wax. Synthetic waxes, such as Fischer-Tropsch wax; naturalwaxes, such as spermaceti, carnauba, ozokerite, beeswax, candelilla,ceresin, esparto, ouricuri, rezowax, and other known mined and mineralwaxes are also suitable for use herein. Olefinic or diene oligomers andlow molecular weight resins may also be used herein. The oligomers maybe polypropylenes, polybutylenes, hydrogenated isoprenes, hydrogenatedbutadienes, or the like, with a weight average molecular weight betweenabout 350 and about 8000.

In one embodiment, a phase change solvent is used as the processing aid.It can be incorporated into the elastomeric composition to lower themelt viscosity, rendering the composition processable at a temperatureof 175° C. or lower, without substantially compromising the elastic andmechanical properties of the composition. Typically, the phase changesolvent exhibits a phase change at temperatures ranging from about 40°C. to about 250° C. Detailed disclosure of the phase change solvents canbe found in U.S. patent application Ser. No. 10/429,432, filed on Jul.2, 2003. In some embodiments, the weight ratio of thermoplasticelastomer to processing oil or processing aid (e.g., a phase changesolvent) in the elastomeric composition typically ranges from about 10:1to about 1:2, preferably from about 5:1 to about 1:1, and morepreferably about 2:1 to about 1:1.

In addition the elastomeric composition can comprise stabilizers and thelike. For example, stabilizers can include both antioxidants and lightstabilizers. Suitable antioxidants include sterically hinderedphenolics. A commercially available antioxidant suitable for use in theelastomeric compositions of the present invention is IRGANOX 1010available from Ciba Specialty Chemicals North America of Tarrytown, N.Y.Suitable light stabilizers include hindered amine light stabilizers. Acommercially available ultraviolet light stabilizer is TINUVIN 123 alsoavailable from Ciba Specialty Chemicals North America.

The elastomeric compositions suitable for use with the present inventionare also substantially tackifier free in order to help insure thatadhesive failure at the pattern roll surface can be reliably achieved.As used herein the term “substantially tackifier free” is intended tomean that the elastomeric composition has less than about 5% by weightof a material commonly recognized in the adhesive arts as a tackifier.As is well known, tackifiers are added to adhesive formulations in orderto increase the adhesion thereof. Materials having commercial utility astackifiers include: rosin resins, cumarone-indene resins, terpene resinsand hydrocarbon resins. Example 1 compares the release properties ofsuitable elastomeric compositions with prior art elastomeric adhesives.

Alternatively, the elastomeric composition may also comprise lowmolecular weight elastomers and/or elastomeric precursors of the abovethermoplastic elastomers, and optional crosslinkers, or combinationsthereof. For example, the thermoplastic elastomers described incopending U.S. patent application Ser. No. 10/610,605, filed in the nameof Ashraf, et al. on Jul. 1, 2003 that comprise an elastomeric blockcopolymer having least one hard block and at least one soft block, amacro photoinitiator, a processing oil, and optionally, a thermoplasticpolymer and/or a crosslinking agent contain such an elastomericprecursor. The weight average molecular weight of the low molecularweight elastomers or elastomeric precursors is between about 45,000 andabout 150,000. In some embodiments, the weight ratio betweenthermoplastic elastomer to low molecular weight elastomers orelastomeric precursors to the thermoplastic elastomers in thecomposition typically ranges from about 10:1 to about 1:2, preferablyfrom about 5:1 to about 1:1, and more preferably about 2:1 to about 1:1.

Suitable elastomeric compositions for use herein form elastomericmembers that are elastic without further treatment and these elastomericcompositions do not include any volatile solvents with boiling pointbelow 150° C. After the elastomeric composition has been applied to thesubstrate, however, post-treatments may be used to improve or enhancethe elasticity and other properties including strength, modulus, and thelike of the resulting elastomeric members. Typically, post-treatmentsconverting the elastomeric compositions into elastomeric members bymethods such as cooling, crosslinking, curing (e.g., via chemical,thermal or radiation means), pressing between nip rolls, andcombinations thereof.

Letterpress Application

The present invention also requires the use of a letterpress applicationsystem which comprises either a pattern roll, a backing roll and anapplicator roll. Such a letterpress application system differs fromsimilar flexographic systems in the structure of the pattern roll. Inthe letterpress system described herein, the pattern roll has asubstantially metallic structure. Such metallic structure is believed tobe necessary for the required heat transfer to provide the cooling ofthe elastomeric composition discussed herein.

The external surface of the pattern roll comprises a predeterminedpattern of raised surface elements. The individual elements can berectilinear, curvilinear, or of any arbitrary shape. For example aregular shape such as circular or rectangular or an irregular shape.Adjacent elements can either have a gap between them or can be connectedto form a continuous pattern.

The individual elements can be parallel or non-parallel to one another.Several elements can be put together to form a component of a finishedarticle (e.g., a disposable diaper).

The raised elements can either be continuous or discontinuous along thesurface of the roll. An example of a continuous pattern is a crosshatchpattern, having MD and CD stripes that run along the entire surface ofthe pattern roll. Another continuous structure would be longitudinalstripes that run in the circumferential direction around the entirepattern roll. An example of discontinuous pattern is horizontal,spaced-apart stripes that run in a direction that is, for example,perpendicular to the circumferential direction.

In some embodiments, the elements can have a largest dimension tosmallest dimension ratio greater than 3, more preferably greater than 10and still more preferably greater than 25. The largest dimension of theelements in one aspect is defined by the largest dimension of an articleproduced using the process described herein. Typically, this largestdimension can vary from about 0.1 mm to about 600 mm. These dimensionsare defined by the dimensions of the distal surface of the raisedsurface elements. Preferably, the walls of the elements are tapered(i.e., narrower at the distal surface thereof than at the base). Suchtaper can ease cleaning of the pattern roll after extended run times.The walls can also be non tapered.

Exemplary processes by which the pattern roll can be provided withraised surface elements include: mechanical engraving (knurling),chemical etching, laser engraving and electromechanical engraving.

The height of the elements is not as critical as in gravure printing,since the material is deposited on the land areas thereof. Too high aheight could result in difficult cleanup if the elastomer inadvertentlyends up in the spaces between the raised surface elements on the patternroll. The height of the elements above the ground surface of the patternroll is suitably between 0.01 mm and 12 mm, preferably between 0.02 mmand 3.0 mm, and more preferably between 0.05 mm and 2.0 mm.

The elastomeric composition is preferably transferred to the patternroll from an applicator roll in order to achieve even distributionacross all of the raised elements and maintain process hygiene. Suchindirect application to the raised pattern elements prevents buildup ofelastomeric composition between the elements as would occur if thethermoplastic resin were applied directly onto the pattern roll byextrusion, spraying and similar direct application methods.

The elastomeric composition can be applied to the applicator roll byimmersing the applicator roll in a bath of molten elastomer, slotcoating, extrusion coating, spraying and other methods as are known tothe art as suitable methods for providing an even coating of a materialacross the width of a roll.

If necessary the CD distribution of the elastomeric composition can beleveled by doctoring. As is known, a doctoring unit operation places anobstruction (e.g., a doctor blade) in direct contact with or at a fixeddistance from a roll or other means of transporting the elastomericcomposition to the pattern roll. The obstruction levels any unevennessin the CD distribution of the elastomer by causing portions to flow fromhigh spots in the distribution to fill low spots. Typically, a doctorblade is a flexible steel blade. In this process, it may be preferableto heat the doctor blade, since the viscosity of the elastomer is highand also viscosity increases quickly if the elastomer is deposited on asurface having a temperature less than the elastomer applicationtemperature. Doctoring also shears the elastomer. This could be abenefit for shear thinning materials, whose viscosity will decreaseduring doctoring, thus aiding the leveling process.

The land areas on the raised surface elements make a kiss contact withthe elastomer layer on the applicator roll. It is important toaccurately control: i) the coating thickness on the applicator roll andii) the gap between the applicator and pattern rolls so as to controlthe amount of elastomeric composition that transfers. If the coating istoo thin or the gap is too large, the pattern roll will not contact theelastomeric film and there will be no transfer. On the other hand, ifthe coating is too thick or the gap is too small, the elastomer will beforced in between the land areas in the pattern roll. This will resultin a poor pattern definition for the transferred elastomeric compositionand may require line shutdown for roll cleanup due to elastomer buildupbetween the raised surface elements.

After the elastomeric composition is delivered to the land area of thesurface elements of the relatively cool pattern roll, it cools downprior to being transferred to the substrate. This cooling, and theresulting increase in viscosity, i.e., cohesive strength, is importantto achieve adhesive failure at the point of transfer to the substrate.It is important to insure that at least a portion of the pattern rollsurface has a surface temperature that is lower than the applicationtemperature so as to provide this cooling. Such cooling is intended toreduce the temperature of the elastomeric composition to less than theorder/disorder temperature thereof so as to increase the cohesivestrength of the composition (The order/disorder temperature is thetemperature where a block copolymer transitions from an ordereddiscernable phase into a single nondiscernable phase and ischaracterized by a substantial reduction in elastic modulus (G′) as maydetermined via rheological measurements as a function of temperature).For typical elastomeric compositions used with the present invention theorder/disorder temperature is at least about 140° C., sometimes 150° C.and even 180° C. or greater. As will be recognized, for high viscosityelastomeric compositions, cooling the deposited elastomer down byseveral tens of degrees Celsius may be sufficient to increase thecohesive strength to a point where the failure is adhesive and it is notnecessary to cool the composition to the order/disorder temperature.Suitably, the surface temperature of the pattern roll is at least about25° C. cooler than the temperature of the applicator roll. Preferably,the surface temperature is at least about 50° C. cooler, more preferablyat least about 65° C. cooler. In order to maintain such reduced surfacetemperature, the pattern roll can be provided with a temperature controlsystem as is known to the art in order to maintain the temperature ofthe pattern roll at a predetermined temperature that is less than theapplication temperature.

Optionally, in order to achieve good release of the elastomer from theraised surface elements, the roll could have a permanent or renewablerelease agent, e.g., a fluorochemical or silicone, on at least the landareas of the surface elements and preferably the entire exterior surfacethereof. A renewable release agent can be added continuously in theprocess at a low add-on level. A suitable renewable release agent isdescribed in copending U.S. patent application Ser. No. 10/151,562,filed on May 20, 2002. Permanent release coatings for process componentsare also known to the art and typically comprise fluoropolymers orsilicone resins.

Many substrates are polyolefin based (polypropylene or polyethylene) andmay be damaged (burnthrough or loss of loft due to calendaring) whenelastomeric compositions are deposited on them. In the process describedherein, however, the chances of damaging the substrate are reduced,since the pattern roll is relatively cool compared to the elastomerdelivery temperature. In short, this process allows transfer of highviscosity elastomers to temperature-sensitive substrates, something thatthe conventional gravure printing process cannot do.

Using the process described herein, it is also possible to cool down thedeposited elastomer substantially more, even to a temperature less thanthe glass transition temperature of one or more of the polymeric blockscomprising the elastomer, on the pattern roll such that the elastomerhas sufficient mechanical strength to take on a solid, web-like form. Inthis form, it would now be possible to peel off the solidified elastomerfrom the pattern roll by applying some tension at the cool end. Thissolidified elastomer can, if desired, be stretched in the machinedirection (e.g., by passing it through a nip between a downstream rollpair that is rotating at a higher speed than the pattern roll), bondedto the substrate, with an adhesive if necessary, and then allowed toretract to deliver live stretch. It is important to note that livestretch cannot be achieved by conventional printing processes, where amore fluid material comes in contact with the substrate.

As noted above, the elastomeric composition is delivered to the patternroll from an applicator roll to insure even coating of the raisedsurface elements. The elastomeric composition is deposited onto theexterior surface of the applicator roll in a molten state from adelivery mechanism which may be selected from the group consisting of aslot coater, a bath, a sprayer, and an extruder. In both instances,however, the elastomeric composition is deposited on the applicator rollin a heated condition, cooled thereon and removed from the roll in arelatively cooler condition.

Without being bound by theory, in the case of letterpress application ofelastomeric materials, oftentimes, when the failure is adhesive, thepeel force needed to peel the elastomer from the pattern roll is muchlower than when the failure is cohesive. See, Gent and Petrich, Adhesionof Viscoelastic Materials to Rigid Substrates, Proc. Roy. Soc. A, vol.310, pp. 433-448 (1969). Also, when the failure is adhesive (alsoreferred to as interfacial failure by Gent and Petrich), the peel forceneeded to peel off the elastomer from the pattern roll is almost changeslittle with increasing viscosity, which is quite beneficial especiallyin the case of high viscosity materials. In these instances, almost allof the elastomer is removed from the elements such that transfer issubstantially complete. As used herein “substantially complete” or“substantially completely” means that no more than about 10%,preferably, no more than about 5%, and more preferably, no more thanabout 1%, of the elastomeric composition is left untransferred to thesubstrate from the letterpress application device, i.e., the roll. Thissubstantially complete transfer is quite advantageous. For example,charring, which is a significant issue with unsaturated elastomersremaining in the dead zones inside gravure elements or patternstructures is minimized.

The Residual Elastomer test described in the TEST METHODS section belowcan be used to determine if the transfer is substantially complete.Residual Elastomer is defined as the weight of the elastomer remainingon the land areas of the pattern roll as a percent of the weight of theelastomer transferred to a length of the substrate equivalent to thepattern roll circumference. The Residual Elastomer value according tothe method is suitably less than 10%, preferably less than 5%, and morepreferably less than 1.

It is desirable to have the elastomeric composition at least partiallypenetrate the substrate at least in some locations, so that theresulting intermediate structure does not delaminate in subsequentprocessing or manufacturing steps or in the finished product.Preferably, the elastomeric composition penetrates only enough toprovide the desired integrity during subsequent processing and use ofthe article. For example, if the substrate is a fibrous substrate, it isbelieved that it is only necessary for the elastomeric compositionpenetrate about one or two fiber diameters to provide such integrity.Additionally, such good bonding within the composite and/or its preformrenders the use of adhesives optional. The degree of penetration may beaffected by several factors: the viscosity of the elastomericcomposition when in contact with the substrate, the porosity of thesubstrate, and the relative surface tension of the substrate and theelastomeric composition. The letterpress application process of thepresent invention allows partial cooling of the elastomeric compositionbefore it contacts the substrate, and thus increases its viscosity anddecreases the degree of penetration into the substrate. Alternatively,the elastomeric composition may be cooled by blowing chilled air/gasonto it prior to or while coming into contact with the substrate or thesubstrate may be cooled, e.g., by providing cooling to the backup roll.In another embodiment, the degree of penetration may be enhanced bypassing the substrate/elastomeric composite between a pair of nip rollsso as to enhance penetration of the elastomeric composition into thesubstrate. The temperature of the nip rolls as well as the applied nippressure provide further control of the degree of penetration.

In certain embodiments, it is possible to vary the amount of elastomericcomposition deposited in different portions of the substrate, therebyvarying the local stretch properties. For example, by changing thepattern on the pattern roll, the resulting elastomeric members canexhibit varying member densities (i.e., numbers of elastomeric membersper unit area) from one area to another area of the composite. In oneexample of varied amount, a repeat unit on the pattern roll couldcorrespond to a key dimension of a substrate (e.g., the length dimensionof an absorbent article that would subsequently be made from thesubstrate) so as to provide different portions of the substrate withdifferent amounts of elastomeric composition. Furthermore, two or moresystems, with different patterns of raised surface elements or differentelastomeric compositions applied to each, can also be used to depositthese elastomeric compositions in different portions of the substrate

Furthermore, it is also possible to combine different depositionprocesses. For example, letterpress application can be combined withspraying or flexo printing, to obtain desired properties in theresulting stretch composites.

One embodiment of a process 100 of manufacturing a stretch composite isillustrated schematically in FIG. 1. This process may include a primaryoperation of making an intermediate structure, which includes the stepsof supplying a first substrate; applying an elastomeric composition ormaterial to the first substrate; and, optionally, joining with a secondsubstrate. Process 100 may optionally include a secondary operation ofincrementally stretching the elasticized substrate to provide additionalextensibility to the substrate.

The primary operation of process 100 is shown in detail in FIG. 1. Asubstrate 34 is provided by a first supply roll 52 and moves in amachine direction through letterpress application system 105 whichcomprises an applicator roll 53, a pattern roll 54 and a back-up roll56. Pattern roll 54 deposits an elastomeric composition that, aftertransfer to the substrate 34, forms elastomeric members thereon. Theelastomeric composition is sufficiently soft at transfer to form anadequately strong bond between the elastomeric composition and thesubstrate to provide an elasticized substrate 35.

The elastomeric composition is delivered to pattern roll 54 fromapplicator roll 53. An elastomeric composition supply means 55 providesa metered amount of the elastomeric composition to applicator roll 53.Supply means 55 can include means 52 (e.g., a doctor blade) to level theelastomeric composition across the CD width of applicator roll 53.Optionally, a second doctor blade can be used to remove residualelastomeric composition from applicator roll 53 for recycle or disposal.

As is shown in FIG. 2, the elastomeric composition is deposited onraised surface elements 258. After transfer, the elastomeric compositionis deposited on substrate 234 as elastic members 260 to form elasticizedsubstrate 235.

Optionally, an additional substrate 236 may be provided by a secondsupply roll 262 and combined with the elasticized substrate 235 via niprolls 264, 266 to sandwich the elastomeric members 260 betweensubstrates 234, 236 to form an intermediate structure 237. If necessary,adhesives may be used to bond the two substrates.

The elasticized substrate 235 and/or the intermediate structure 237 maybe subjected to additional treatments such as cooling, pressing (e.g.,passing between a pair of nip rolls), crosslinking, curing (e.g., viachemical, thermal, radiation methods), and combinations thereof, toenhance the elastic and mechanical properties of the elastomericcomposition deposited thereon and of the resulting intermediatestructure.

An exemplary secondary operation suitable for use in process 100 isshown as forming station 106 in FIG. 1 and in greater detail in FIG. 3.This secondary operation includes a forming station 106 whichincrementally stretches the intermediate structure 37 (or theelasticized substrate 35) to the extent that the substrate ispermanently elongated and intermediate structure 37 is converted intostretch composite 38. Due to this structural change, the substrate has areduced resistance to stretch and the elastomeric members are able tostretch to the extent provided by the permanent elongation of thesubstrate.

The aforementioned process, known as “ring-rolling,” to provideadditional cross direction extensibility is shown in FIG. 3 where a pairof corrugated interengaging rolls 108, 109 are used to permanentlyelongate the substrate as it passes through nip 107 to reduce itsresistance to stretch, may be a desirable incremental stretchingoperation of the present invention. Similarly, “gear rolling” can beused to provide incremental machine direction stretch. The resultingcomposite has a greater degree of stretchability in the portions thathave been subjected to such additional process steps. Thus, suchsecondary operations provide additional flexibility in achieving stretchproperties in localized portions of the stretch composite.

Methods for imparting stretchability to an extensible or otherwisesubstantially inelastic material by using corrugated interengaging rollswhich incrementally stretch in the machine or cross-machine directionand permanently deform the material are disclosed in U.S. Pat. Nos.4,116,892, 4,834,741, 5,143,679, 5,156,793, 5,167,897, 5,422,172, and5,518,801. In some embodiments, the intermediate structure may be fedinto the corrugated interengaging rolls at an angle with respect to themachine direction of this secondary operation. Alternatively, thesecondary operation may employ a pair of interengaging grooved platesapplied to the intermediate structure under pressure to achieveincremental stretching of the intermediate structure in localizedportions.

Extensibility may also be imparted to the substrate via necking asdescribed in U.S. Pat. Nos. 5,226,992 and 5,910,224. In this process,the substrate is necked in one direction by applying tension, and theelastomer is printed while the substrate is still in the necked state.If necessary, this laminate can be incrementally stretched to furtherenhance the stretch properties. Another method of impartingextensibility is by consolidation as described in U.S. Pat. Nos.5,914,084 and 6,114,263. As described, consolidation involves feeding aneckable nonwoven in a first direction, subjecting the nonwoven toincremental stretching in a direction perpendicular to the first,applying a tensioning force to the nonwoven to neck the nonwoven,subjecting the nonwoven to mechanical stabilization to provide astabilized, extensible, necked nonwoven. Additionally, the requisiteincremental stretching may be achieved by a combination of thestretching techniques detailed herein. As with necking, this laminatecan optionally be incrementally stretched to further enhance stretchproperties.

It is desirable that the extensible substrate does not exhibitmeaningful resistance to stretch when the composite is subjected to atypical strain under in-use conditions. In-use strains experienced bythe composite are due to the stretching when the article is applied toor removed from a wearer and when the article is being worn. Theextensible substrate can be pre-strained to impart the desiredstretchability to the composite. Typically, when the extensiblesubstrate is pre-strained to about 1.5 times the maximum in-use strain(typically less than about 250% strain), the extensible substratebecomes permanently elongated such that it does not exhibit resistanceto stretch within the range of in-use strain and the elastic propertiesof the composite are substantially provided only by the elastomericmembers in the composite.

Suitable uses for the stretch composites that result from the processesof the present invention include disposable articles. Exemplarydisposable articles include diapers, training pants, adult incontinencearticles, sanitary napkins, garments like gloves, aprons, smocks, socks,etc. These disposable articles may comprise a stretch region that isselected from the group consisting of an ear, leg cuff, waist band, backpanel, front panel, side panel, and combinations thereof, and thesestretch regions comprise the stretch composites that are manufacturedvia the process of the present invention.

TEST METHODS Peel Force

The peel force test measures the force required to peel an elastomericcomposition in film form from a smooth stainless steel plate at roomtemperature.

Apparatus

-   Stainless Steel Plate: M^(c) Master-Carr (Cleveland, Ohio), catalog    number 8983K62, conforms to ASTM A240 The smooth stainless steel    plate is made of 304 stainless steel and has a #2B finish; width=100    mm, length=75 mm, thickness=0.060-   Silicone Rubber Sheet: M^(c) Master-Carr #8979K111, high temperature    silicone rubber, 1/32″ thick, 49 A Durometer-   Release Paper Paul N. Gardner Company, catalog #PC-RP-1K,    8.63″×11.25″, ASTM D 4708/2370/1353-   Hand Roller: A suitable roller can be fabricated as a 68 mm diameter    steel roll having a 6 mm thick coating of hard rubber (65 Shore A)    thereon. The finished roll has a weight of 2250 grams, a width of    6.35 cm.-   Mylar Film: a 2 mils (0.05 mm) This Mylar film should be slightly    wider and longer than the elastomer in order to ensure that it fully    covers it.-   Tensile Tester: A suitable instrument is available from MTS Systems    Corp. of Cary, N.C. as model Alliance RT/1.-   Sample Support: The support 400 used to hold the stainless steel    plate during execution of this method is shown in FIG. 4 a. It is a    bent from a 120 mm×110 mm stainless steel plate so as to have the    following dimensions:    -   Plate Width: 110 mm    -   First vertical portion 410-80 mm    -   Horizontal portion 420-25 mm    -   Second vertical portion 430-15 mm    -   FIG. 4 b shows one of a pair of clamps 440 used to insure that        the stainless steel plate remains in stable contact with support        400 throughout the test. The clamps 440 may be conveniently made        by bending 12 mm wide stainless steel into a rectangle 450        having a width of 111 mm (i.e., slightly wider than support        400)×5 mm deep. The clamps are also provided with a screw        apparatus 445 for providing tension against the support 400.        Sample-   Elastomeric Film: The film sample must have exactly the same    composition as the elastomeric composition that is applied using the    claimed process. Sample width is 2″ (50.8 mm) wide by a minimum of    75 mm long by 14 mils±2 mils (0.356 mm±0.05 mm) thick

The films are prepared by:

-   -   1) Weighing approximately 12 grams of the elastomeric        composition of interest;    -   2) Compression molding the composition by placing the        pre-weighed material between two pieces of 0.010 inch (0.03 mm)        caliper PTFE (Teflon®) film;    -   3) Placing the film “sandwich” between preheated aluminum plates        that are inserted into a Carver Press model 3853-0 with heated        plates set to approximately 160° C.;    -   4) Heating the material for 3 minutes and then pressing it        between the plates with an applied pressure of 2500 psi;    -   5) The formulation is allowed to flow under pressure for 30        seconds;    -   6) Quenching the resulting film to ambient temperature; and    -   7) Cutting the film into three equal portions.    -   8) Each portion is placed between films of PTFE and preheated        aluminum plates and allowed to heat up to 160° C. for 1 minute        in the Carver press before 2,000 psi of pressure is applied.    -   9) The formulation is allowed to flow under this pressure for 30        seconds.    -   10) The pressure is removed and the sample is rotated 90° and        inserted back into the press and immediately 3,000 psi of        pressure is applied.    -   11) The formulation is again allowed to flow for 30 seconds. The        pressure is removed and the sample is flipped and inserted back        into the press and immediately 4,000 psi of pressure is applied.    -   12) The formulation is again allowed to flow for 30 seconds.    -   13) The pressure is removed and the sample is rotated 90° and        inserted back into the press and immediately 5,000 psi of        pressure is applied.    -   14) The formulation is again allowed to flow for 30 seconds.    -   15) After the final pressing, the film is quenched to ambient        temperature.    -   16) If necessary, two or more plies of material prepared        according to steps 1-15 are laminated by layering the plies and        repeating steps 8-15 to achieve a final sample thickness of        0.36±0.05 mm.    -   17) The films are cut into proper sample size according to the        test methods described hereinabove.        Method    -   1) Place the smooth stainless steel plate (SS plate) on a metal        support plate.    -   2) Place the silicone rubber sheet adjacent to the smooth SS        plate. This silicone rubber sheet should have about the same        thickness as the smooth SS plate.    -   3) Place the sample of the elastomeric film of interest on the        smooth SS plate such that it is at least 50 mm on the smooth SS        plate and at least 25 mm on the silicone rubber sheet.    -   4) Place the release paper on top of the elastomeric film and        apply pressure with the hand roller. The hand roller is rolled        over the test sample 10 times (1 time=1 forward and 1 return        movement). The pressure applied is just the weight of the hand        roller.    -   5) Remove the release paper and put the test sample on a SS        support plate that is placed on a hot plate maintained at a        temperature greater than the order/disorder temperature for the        composition. It is necessary to heat the elastomer well above        its order/disorder temperature in order to ensure that the        elastomer is soft enough to bond with the smooth stainless steel        plate. A temperature of 160 C should be sufficient for most        compositions of interest.    -   6) Heat the test sample on the hot plate for 10 minutes±1        minute.    -   7) Remove the SS support plate along with the test sample and        place it on a block of steel that is at room temperature.    -   8) Ten seconds after removal from the hot plate, place the Mylar        film on the elastomer and apply pressure with the roller 10        times as before.    -   9) Allow the setup to cool down in air to room temperature.    -   10) Place the smooth SS plate, along with the elastomer and        Mylar film, in the peel test grips on a tensile tester. The peel        angle is 180 degrees and the measurements are made at room        temperature.    -   11) Peel off the elastomer from the smooth SS plate at 10        inches/minute. The load increases first and then reaches a        steady value.    -   12) Record this constant peel force and report it in gram        force/cm width of the elastomer.    -   13) Repeat for a total of at least 3 replicates.    -   14) Report the average peel force and the standard deviation of        the recorded measurements.        Residual Elastomer

This method is intended to measure the amount of residual elastomer onthe pattern roll and uses this data to determine residual elastomer. Inprinciple, a fluorescent material is incorporated into the elastomericcomposition of interest and a curve relating amount of the compositionto fluorescence is created. This curve is then used to relatemeasurements of fluorescence to the amount of thermoplastic elastomerremaining on the raised surface elements.

Materials

-   Fluorescer: A suitable fluorescent material is available from UV    Process Supply Inc. of Chicago, Ill.    Apparatus

Any suitable apparatus capable of providing appropriate illumination andmeasuring the intensity of the emitted light may be used. The apparatusshould be as compact as possible within the constraint of themeasurement requirements.

-   Fluorimiter: Capable of receiving and measuring the intensity of    emitted light from the fluorescent material. The fluorimeter should    include an appropriate optical filter tuned to the characteristic    wavelength of the light emitted by the fluorescer.-   Exciter: Capable of providing light at the characteristic wavelength    that is most efficient for energy transfer to the fluorescer. The    exciter should include an optical filter to define the wavelength of    the light used to illuminate the fluorescer.    Sample-   Elastomer: Take a sample of elastomer that is at least three times    the estimated volume of the elastomer supply apparatus on the    application system being evaluated.    Determination of Fluorescer Concentration-   1. Prepare a 0.01% solution of the elastomer in a suitable solvent.-   2. Prepare a known concentration solution of the fluorescer in the    same solvent.-   3. To aliquots of the elastomer solution add aliquots of the    fluorescer solution so as to provide mixed solutions that are    equivalent to 0.01% solutions of elastomer that has had fluorescer    at concentrations of 0.1%, 0.5%, 1%, 2% and 5% added thereto.-   4. Calibrate the fluorimeter and exciter according to the    manufacturer's instructions.-   5. Determine the intensity of emitted light from each of the mixed    solutions (I_(0.1)−I_(0.8)).-   6. Choose a fluorescer concentration that provides an acceptable    signal to noise ratio.    Preparation of Elastomer

The elastomer and the fluorescer are compounded so as to thoroughlydisperse the fluorescer in the elastomer at the lowest concentrationnecessary to achieve an acceptable signal to noise ratio as determinedfrom the intensity/concentration curve. GLS Corporation of M^(c) Henry,Ill. is a suitable compounder for this operation.

Preparation of Standard Fluorescence Curve

-   1. Dissolve portions of the compounded elastomer using the    fluorescer concentration as determined above in a suitable solvent    at concentrations of 0.01%, 0.05%, 0.1%, 0.5% and 1%.-   2. Measure and record the intensity of the fluorescence from each    sample using the fluorimeter-   3. Repeat steps 1 and 2 for two additional sets of samples.-   4. Plot a curve of the concentration vs. the average intensity at    each concentration.    Residual Elastomer Determination-   1. Remove the noncompounded elastomer from the elastomer supply    apparatus.-   2. Fill the elastomer supply apparatus with the compounded    elastomer.-   3. Start up the letterpress application system.-   4. Run the letterpress adhesive application system under production    operating conditions until at least two supply system volumes of    compounded elastomer have been consumed.    At the completion of steps 1-4 and before the remainder of the    compounded elastomer is consumed conduct the following measurements    while the system is running under production operating conditions.    -   5. Retract the applicator roll so as to prevent transfer of        elastomer from the applicator roll to the pattern roll.    -   6. Continue to run the process under production operating        conditions with the applicator roll retracted for at least 20        revolutions of the pattern roll (approximately 10-30 seconds).    -   7. Conduct a controlled line shutdown.    -   8. Collect the product produced during the period in a manner        that the sequence of products is maintained.    -   9. Choose a pattern for further evaluation. As used herein a        “pattern” is a portion of the elastomeric composition that has        been deposited on the surface of the substrate from one or more        raised pattern elements wherein the elements are located on a        specific portion of the pattern roll.    -   10. From the collected product, identify the first pattern        produced where elastomer transferred thereto is visibly reduced.        This pattern is indicative of the point in the process flow        where the applicator roll was retracted.    -   11. Collect 20 individual patterns that were produced after the        first pattern with a visible reduction in transferred elastomer        being careful to maintain the patterns in production order.    -   12. Collect 20 individual products that were produced before the        first pattern with a visible reduction in transferred elastomer        being careful to maintain the products in production order.    -   13. Number the samples 1 to 41 with sample number 1 being the        that pattern that was produced with the greatest duration of        time before the applicator roll was retracted and sample 41        being that pattern that was produced with the greatest duration        of time after the applicator roll was retracted. As will be        recognized, sample 21 is the sample visually identified in step        8.    -   14. Extract, samples 1-25 using a suitable solvent.    -   15. Measure the intensity of the fluorescence of the extracts of        each sample. If necessary, the extracts can be concentrated        using known methods to increase the measured intensity.    -   16. Using samples 1-20, determine the process capability limits        (mean intensity±3 standard deviations) of the application        process for the pattern chosen.    -   17. Compare the intensity of sample 21 to the process capability        limits. If the intensity of sample 21 is within the process        capability limits, proceed to step 16. If not, move backward        through (i.e., toward sample 1) the samples to determine the        first sample having an intensity within the process capability        limits.    -   18. For sample 21 (or alternative starting point as determined        in step 15) and the next 5 samples in sequence determine the        elastomer add-on (Add-On Wt₂₁−Add-On Wt₂₆) using the standard        curve developed using the method described above.

${19.\mspace{14mu}{Percent}\mspace{14mu}{Residual}} = {\frac{{\sum\limits_{22}^{26}{Add}} - {OnWt}_{i}}{{\sum\limits_{21}^{26}{Add}} - {OnWt}_{i}} \times 100}$

-   -   20. Repeat Steps 5-15 three more times.    -   21. Report average Percent Residual Elastomer, the individual        calculated Percent Residual Elastomer values and all data used        to calculate them.

Example 1

This example compares the properties of commercially available adhesives(elastomeric and nonelastomeric), a thermoplastic elastomer andexemplary non-adhesive elastomer compositions.

Peel Force Description (N/cm) Type H2737¹ 5.54 Adhesive H2031² 14.40Adhesive Vector 4211³ 2.31 Non-adhesive First non-adhesive elastomer⁴0.23 Non-adhesive Second non-adhesive elastomer⁵ 0.16 Non-adhesive¹Elastomeric adhesive from Bostik Findley of Wauwatosa, WI ²Adhesivefrom Bostik Findley ³Styrene/isoprene/styrene block copolymer availablefrom Dexco Polymers LP, Houston, TX ⁴Vector 8508^(a) 20% Low MolecularWeight Thermoplastic Elastomer^(b) 50% Drakeol 600^(c) 25% MPhotoinitiator^(d)  5% ^(a)Styrenic block copolymer from Dexco Company,Houston, TX ^(b)Experimental Styrenic-isoprene-styrene block copolymerfrom Dexco ^(c)Mineral oil from Pennzoil Co., Penrenco Div., Karns City,PA ^(d)Experimental sample from National Starch and ChemicalsBridgewater, NJ ⁵Septon 4033^(a) 40% SHF 401^(b) 40%Dioctyldodecylterephthalate oligimer 20% ^(a)Styrenic block copolymerfrom Kuraray America, Inc. of New York, NY ^(b)Poly α olefin syntheticoil from ExxonMobile Chemical Co., Huston, TX.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process of manufacturing a stretch composite,the process comprising the steps of: a) providing a polyolefin basedsubstrate, wherein the substrate has a thickness between about 0.05millimeters and about 2 millimeters; b) providing a letterpress adhesiveapplication system comprising a pattern roll and an applicator roll; c)depositing a molten, non-adhesive, elastomeric composition onto theapplicator roll; d) transferring only a portion of the elastomericcomposition that is on the applicator roll, from the applicator roll tothe pattern roll, by contacting the pattern roll with the elastomericcomposition that is on the applicator roll; and e) transferringsubstantially all of the elastomeric composition from the pattern rollto the substrate, by contacting the substrate with the elastomericcomposition that is on the pattern roll, without damaging the substrate.2. The process of claim 1, wherein the providing of a polyolefin basedsubstrate comprises providing a polypropylene based substrate.
 3. Theprocess of claim 1, wherein the providing of a polyolefin basedsubstrate comprises providing a polyethylene based substrate.
 4. Theprocess of claim 1, wherein the providing of a polyolefin basedsubstrate comprises providing a substrate, and wherein the substrate hasa thickness between about 0.1 millimeters and about 1 millimeter.
 5. Theprocess of claim 1, wherein the providing of a polyolefin basedsubstrate comprises providing a substrate, and wherein the substrate hasa thickness between about 0.1 millimeters and about 0.5 millimeters. 6.The process of claim 1, wherein: the transferring of only a portion ofthe elastomeric composition takes place at a first temperature; and thetransferring of substantially all of the elastomeric composition takesplace at a second temperature that is less than the first temperature.7. The process of claim 6, wherein the second temperature is at leastabout 25 degrees Celsius less than the first temperature.
 8. The processof claim 6, wherein the second temperature is at least about 50 degreesCelsius less than the first temperature.
 9. The process of claim 6,wherein the second temperature is at least about 65 degrees Celsius lessthan the first temperature.
 10. The process of claim 6, wherein thesecond temperature is less than or equal to an order/disordertemperature of the elastomeric composition.
 11. The process of claim 6,wherein the second temperature is less than or equal to anorder/disorder temperature of the elastomeric composition, and whereinthe order/disorder temperature is at least about 180 degrees Celsius.12. The process of claim 6, wherein the second temperature is less thanor equal to an order/disorder temperature of the elastomericcomposition, and wherein the order/disorder temperature is at leastabout 150 degrees Celsius.
 13. The process of claim 1, wherein thetransferring of substantially all of the elastomeric compositioncomprises transferring at least about 90% of the elastomeric compositionfrom the pattern roll to the substrate.
 14. The process of claim 1,wherein the transferring of substantially all of the elastomericcomposition comprises transferring at least about 95% of the elastomericcomposition from the pattern roll to the substrate.
 15. The process ofclaim 1, wherein the transferring of substantially all of theelastomeric composition comprises transferring at least about 99% of theelastomeric composition from the pattern roll to the substrate.
 16. Aprocess of manufacturing a stretch composite, the process comprising thesteps of: a) providing a first substrate, the substrate moving in amachine direction, wherein the substrate has opposing first and secondsurfaces; b) providing a letterpress adhesive application system, theletterpress adhesive application system comprising a pattern roll and anapplicator roll, each of the rolls having an exterior surface with aroll surface temperature, a portion of the exterior surface of thepattern roll comprising a predetermined pattern of raised surfaceelements; c) depositing a molten, non-adhesive, elastomeric compositiononto the exterior surface of the applicator roll, the composition havingan application temperature, the application temperature being greaterthan the pattern roll surface temperature; d) transferring a portion ofthe composition from the applicator roll to a distal surface of theraised elements so as to surface coat the raised elements, wherein thecomposition cohesively fails such that a portion of the composition alsoremains on the applicator roll; and e) cooling the transferred portionto a temperature between the application temperature and the patternroll surface temperature causing a cohesive strength of the compositionto increase such that the cohesive strength is greater than a peel forceof the composition; and f) contacting the first surface of the substrateand the surface coated raised elements and substantially completelytransferring the elastomeric composition from the distal surface of theraised surface elements to the first surface.
 17. The process of claim16, wherein the exterior surface of the pattern roll has a temperaturethat is at least 5° C. lower than at least one of the applicator rollsurface temperature and the application temperature.
 18. The process ofclaim 16, wherein the composition is deposited by a supply meansselected from the group consisting of a slot coater, a bath, a sprayer,and an extruder.
 19. The process of claim 16, wherein the elastomericcomposition comprises thermoplastic elastomers and mineral oils and issubstantially tackifier free.
 20. The process of claim 16, wherein theat least a portion of the components of the elastomeric compositioncomprise crosslinkable materials.
 21. The process of claim 16, whereinthe elastomeric composition comprises from about 1 to about 70 wt% of aprocessing oil.
 22. The process of claim 16, wherein the elastomericcomposition comprises from about 1 to about 50 wt% of a non-elastomericthermoplastic polymer.
 23. The process of claim 16, wherein thesubstrate is stretched in the machine direction so as to neck thesubstrate in a cross machine direction prior to transfer of thecomposition.
 24. The process of claim 16, wherein the substrate isincrementally stretched after the transfer of the composition so aspermanently elongate at least a portion thereof.
 25. The process ofclaim 16, wherein a second substrate is contacted with the elastomericcomposition after the transfer of the composition.
 26. A process ofmanufacturing a stretch composite, the process comprising the steps of:a) providing a polyolefin based substrate; b) providing a letterpressadhesive application system comprising a pattern roll and an applicatorroll; c) depositing a molten, non-adhesive, elastomeric composition ontothe applicator roll; d) transferring only a portion of the elastomericcomposition that is on the applicator roll, from the applicator roll tothe pattern roll, by contacting the pattern roll with the elastomericcomposition that is on the applicator roll; and e) transferring at least95% of the elastomeric composition from the pattern roll to thesubstrate, by contacting the substrate with the elastomeric compositionthat is on the pattern roll, without damaging the substrate.